Lincoln Electric 5000 manual Troubleshooting, Possible Areas, Symptoms

Page 42

E-1

 

TROUBLESHOOTING

E-1

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

MISADJUSTMENTS(S)

COURSE OF ACTION

 

 

 

 

 

 

PROBLEMS

A.No generator power or welding out- 1. Open lead in flashing or field circuit. 1. Refer to wiring diagram. put.

-check lead 202C (brown) connection at oil-gard switch in engine block.

-check (green) GNDC lead con- nected to bearing end bracket.

2.

Open flashing diode (D1)

2.

Check continuity in forward direction

 

 

 

202C (brown) and 202B (red)

3.

Faulty brushes.

3.

Check continuity and wear of brush.

 

 

 

Replace brush if necessary.

4.

Faulty rheostat (R1).

4.

Rheostat resistance should be

 

approximately 3 ohms when current

 

 

 

control dial is set at “70 amps”.

5.

Faulty field rectifier (D1).

5.

Replace field rectifier.

 

 

 

6.

Faulty capacitor (C1).

6.

Replace capacitor.

 

 

 

7.

Faulty stator field winding.

7.

Disconnect lead 7A (blue) at D1 and

 

check for continuity between leads

 

 

 

 

 

 

7A and 9A (blue).

8.

Faulty rotor.

8.

Remove brushes and check rotor

 

 

 

resistance between slip rings. It

 

 

 

should read approximately 7 ohms.

 

 

 

See “Generator / Welder

 

 

 

Maintenance” section for brush

 

 

 

installation procedure.

9. Dirty slip rings

9. Clean slip rings with a fine git emery

 

 

 

paper.

 

 

 

 

B. Generator power is available but 1.

Loose connection to output stud.

1.

Check output studs and firmly tight-

unit will not weld.

 

 

en all connections.

 

2.

Clean work clamp area of work to a

2.

Work not connected.

 

 

 

shiny metal.

3.

Electrode holder loose.

3.

Check all electrode holder connec-

 

 

 

tions.

4.

No open circuit voltage at output

4.

Refer to wiring diagram and check

 

studs. Open lead in weld circuit.

 

leads W1, W1A, & W2 (black).

5.

Faulty reactor (L1).

5.

Check resistance from start to end of

 

 

 

aluminum coil. Replace reactor if

 

 

 

necessary.

6.

Rheostat (R1) lead broke

6.

Refer to wiring diagram.

 

 

 

-

check lead 200 (red).

 

 

 

-

check lead 202B (red).

 

 

 

-

check rheostat tabs.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER ARC 5000

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Contents Power ARC Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Installation Technical Specifications Power ARCSafety Precautions Location and VentilationStoring Stacking TiltingLifting Assembly of Wheels and Handle to the Tube Frame Fuel PRE-OPERATION Engine ServiceOIL Spark ArresterElectrical Output Connections Welding Cable ConnectionsAuxiliary Power Receptacles Cable InstallationMachine Grounding Plugs and HAND-HELD Equipment Power Cord Connections to TWIST- Lock PlugsPremises Wiring Circuit BreakersThese Devices Without Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Welding CapabilityLimitations Controls and Settings GENERATOR/WELDER ControlsFigure B.2 Gasoline Engine Controls Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine For a HOT Engine Stopping the EngineBREAK-IN Period For Best Engine StartingTo USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.3 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsControl Function / Operation Current Control Dial To USE the Power ARC 5000 for Stick WeldingWelding Operation After YOU Finish the WeldWelding Guidelines Stick Welding What Happens in the Arc? Figure B.4 The welding arcCorrect Welding Position Correct Arc Length Correct Way to Strike An ArcCorrect Welding Speed Practice Common MetalsTypes of Welds Multiple Pass Welds PenetrationFillet Welds Welding in the Vertical PositionVertical-Up Welding Vertical-Down WeldingWelding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce WearWelding Cast Iron Cast Iron Plate PreparationHigh-Speed Group AWS E6013 Selecting ElectrodesOut-of-Position Group AWS E6011 Low Hydrogen Group Stable-Arc E7018Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Briggs and Stratton AccessoriesEngine Maintenance MaintenanceRoutine and Periodic Maintenance Engine AdjustmentsFigure D.3 Clean Cooling System Clean AIR Filter PRE-CLEANERTable D.2 Engine Maintenance Parts Part Part NumberGENERATOR/WELDER Maintenance Figure D.6. Brush Removal and ReplacementFigure D.7. Major Component Locations Troubleshooting SymptomsPossible Areas Generator POWER, Always Not RUN Engine Without AN Diagrams Wiring Diagram Power ARCDimension Print Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Warnung
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